Sectionally supported wall



F. W. ANTILL SECTIONALLY SUPPORTED WALL Feb, 15, 1944.

2 Sheets-Sheet 1 Filed Dec 13, 1940 INVEN OR. M4: BY

Feb 15, 1944. R w, ANTILL SECTIONALLY SUPPORTED WALL Filed Dec. 13, 19402 Sheets-Sheet 2 Patented Feb. 15, 1944 2,341,971 SECTIONALLY SUPPORTEDWALL Philip Washington Antill, Ridgefleld Park, N. J., assignor toAmerican Arch Company, New York, N. Y., a corporation 01' DelawareApplication December 13, 1940, Serial No. 370,013

13 Claims.

The present invention relates to sectionally supported wall structuresand has particular reference to sectionally supported walls 01'refractory blocks or tile for furnaces or other high temperaturechambers.

Amongst the several objects of the invention are; to provide a novelform of sectionally supported wall structure which is simple andrelatively inexpensive, which involves the minimum of metallicsupporting structure for the refractories, which provides a plurality ofindependently supported sections or .belts, each built up of courses ofrefractory blocks and in which the several sections as well as theindividual courses of each section are restrained against lateraldisplacement without use of special metal retaining members or otherparts specially employed for this'purpose, in which the full depth ofrefractory material is maintained throughout the area of the wall, whichmay be built up to provide walls of different thickness with the minimumnumber of refractory shapes, in which horizontal expansion of therefractories in the plane of the wall on the furnace sid thereof may bereadily provided for and insured, in which effective sealing againstleakage of gases through the wall is provided for, in which the outerside of the wall presents a substantially clear and unobstructed planesurface well adapted for the application thereto of insulating materialin block form and in which simple and inexpensive means is providedwhereby insulating material of difierent thicknesses may readily beapplied to the wall as desired.

As will hereinafter be pointed out more in detail, the above and otherand further objects are obtained by the provision of a wall structureconsisting of a suitable outer metal supporting structure includinghorizontally extending, vertically spaced hanger members forindependently supporting the several sections or belts of the refractorywall structure, combined with a refractory structure in which eachseparately supported section consists of a series of courses ofinterengaging refractory blocks which mutually engage each other toprevent lateral displacement of the courses relative to each other inthe same section and in which the lateral movement of the section as awhole relative to the superjacent section is restrained by engagementbetween certain of the blocks in the lowermost or supporting course ofthe superjacent section with blocks immediately below them andconstituting a part of the top course of the immediately subjacentsection.

For a better understanding of the detailed nature of the invention andpreferred means for carrying it into eflect, reference may best be hadto the ensuing portion of this specification and the accompanyingdrawings in which are described and illustrated by way of examplesuitable iorms of wall structure embodying the invention.

In the drawings:

Fig. 1 is a view partly in vertical section and partly in elevation of awall structure embodying the principles of the invention, taken on theline i-- i of Fig. 2;

Fig. 2 is an elevation taken at right angles to Fig. 1 looking from theright of the latter figure;

Fig. 3 is a section taken on the line 3-3 of Fig. 2;

Fig. 4 is a section taken on the line l4 of Fig. 1;

Fig. 5 is a fragmentary view, looking from below, and showing one of thehanger members illustrated in Figs. 1 and 3;

Figs. 6 and 'l are perspective views of the supporting and supportedblocks respectively employed in the wall shown in Figs. 1 and 2;

Fig. 8 is a view similar to Fig. 1 and taken on the line 88 of Fig. 9,showing the construction of a wall embodying the invention and ofgreater thickness than the wall shown in Fig. 1;

Fig. 9 is a view taken on the line 9-9 of Fig. 8;

Fig. 10 is a section taken on the line Ill-Ill of Fig. 9;

Fig. 11 is a perspective view of a filler block used in the wall shownin Figs. 8 and 9;

Fig. 12 is a fragmentary section showing a form of hanger memberdifferent from that illustrated in Fig. 1;

Fig. 13 is a perspective view of a form of refractory supported blockproviding for horizontal expansion in the plane of the wall; and

Fig. 14 is a similar view of supporting block embodying the horizontalexpansion feature.

Referring now more particularly to the embodiment illustrated in Figs. 1to '7, the outer supporting structure is formed by a series of verticalbuck stays, one of which is shown at III. These may be of any desiredsection and in the embodiment shown are I-beams.

A series of horizontally extending vertically spaced supporting membersl2, which in the embodiment shown are of channel section, are secured tothe buck stays by any suitable means such as the bolts M, and mayfurther be'vertically supported by angles l6 welded or otherwise securedto the buck stays.

A series of horizontally extending vertically spaced hanger members,preferably in the form of castings is, are fastened to the horizontallyextending channels l2 by means or bolts 20, these hanger .castingspreferably lking horizontally spaced from each other for reasons whichwill later be more fully explained.

The hanger castings II are of generally chan- 'nel shape in section,consisting of a web portion a, a top flange portion I81), and a bottomflange portion lie. with the web portion of the hanger castings boltedto the horizontal supporting members, these castings provid a series ofsockets adapted to receive and support the supporting blocks 20 whichare. of oblong rectangular shape and which are provided withtransversely extending projections 20a and 20b on two of their sides andcorresponding transversely extending grooves or recesses 20c and 20d ontheir remaining two sides.

As will be seen more clearly from Fig. l, the upper flange portions libof the hanger castings are provided with overhanging lips "d at theirinner edges. The supporting blocks 20 are inserted endwise into therecesses provided by the hanger castings and as will be observed fromFig. 1, the upper and lower faces of the blocks are engaged respectivelyby the upper and lower flange portions of the hanger castings, with theprojections 20a on the upper faces of the blocks engaging the recessesprovided by the lips |8d oi the hanger castings to provide not onlyvertical support for the supporting blocks, but to also provide supportagainst tilting thereof. As will be seen from Fig. 3, the length of eachhanger casting is such that it supports a plurality of adjacent blocks2t. In the embodiment illustrated, four such blocks are supported byeach casting.

The supporting blocks 20 extend inwardly of the furnace beyond thehanger members for a substantial distance, in the present instance abouthalf of the length of the blocks extending beyond their supports. Thesesupporting portions of blocks 20 form the support for the supported tile22 which are also of oblong rectangular form and are provided withprojections 22a on two sides and corresponding grooves or recesses 22b nthe two ends. As will be seen from Fig. '7, the projections and groovesextend longitudinally of the blocks. The supported blocks 22 are laid incourses on the supporting blocks, the projections and grooves ofadjacent blocks in the same course and of the blocks in adjacent coursesinterenseams to prevent movement of the blocks relative to each otherlaterally toward or away from the furnace. Obviously, the number ofcourses of supported blocks in each sectionmay be varied as desired andin erecting the wall the vertical spacing between hangers I8 isselected, with respect to the number and thickness of supported blocks,so that a suitable vertical clearance space is left between the upperface of the top course of each section and the lower face of the bottomor supporting course of the section immediately above to allow forindependent expansion and contraction of the several sections. Thisspace is filled with suitable refractory material, the nature of whichwill permit of the desired movement of the sections relative to eachother under the influence of expansion and contraction.

For practical considerations of manufacture, handling duringtransportation, and erection it is highly desirable that the grooves andprojections on the several blocks be shaped in section 50 that theprojections will be suihciently strong to be not easily broken. Thisrequires that the projections in section be relatively low and thepreferred section is semi-circular as illustrated in the figures. Intheory the projections 22a on the upper side of the top course ofsupported block of each section engage in the grooves 22d in the bottomfaces of the supporting blocks of the section next above and thusprovide the required lateral engagement between adjacent sectionsnecessary to prevent the possibility of a section being tilted inwardlyof the wall due to force applied from the outside. In practice,interengagement of this nature does occur to some extent, but because ofthe clearance or expansion space 24 which it is necessary o providebetween sections and the relatively low height of the projections andcorresponding shallow grooves which are desirable, the interengagingareas at this place constitute only a part of the normal fullinterengaging area. Refractory blocks used in the construction of wallsof the kind under consideration are ordinarily not'precisely uniform indimensions and the erection of such walls is not on what may be termed aprecision basis. Taking into account the variations in the size of theparts and the variations in Spacing which may occur in erection,together with variations in expansion and contraction, it will beapparent that in many instances the clearance space 24 may approach oreven equal the height of the projections on the blocks so that nolateral interengagement. or only a very slight and easily overcomeinterengagement, is provided at one or more places in the wall.

In order to overcome this diiilculty and to provide a positiveinterengagement in all cases, regardless of variations in dimensions ofparts or in erection, the present invention provides a very simple andeffective interlock between adjacent sections through the medium ofcertain of the supporting blocks that are not supported by the hangercastings l8. By spacing these castings, certain of the blocks 20 arepermitted to slide vertically relative to the adjacent supported blockswith which they interengage, so as to be supported directly by blocks ofthe top course of the subjacent section. As shown in Fig. 2, the spacingof the hangers is such that groups of four blocks each, indicated at201, are supported by adjacent hanger castings, while intermediate thesegroups are groups 20: of two blocks each which rest directly upon thetop course of blocks 22 of the subjacent section. The blocks in thegroups 20: provide full interengaging contact, as will be observed fromFig. l, with the subjacent section and above these blocks clearancespace 24' is provided similar to the space 24 below the supported groups201. The blocks in the groups 28:, while not restrained against lateralmovement by engagement with hanger castings, are effectively restrainedagainst such movement by interengagement of their grooves andprojections with the groovesand projections on the sides adjacent blocksin groups 201 which are restrained against lateral displacement, andconsequently a fully effective interengagement operating to positivelyhold the subjacent section against lateral displacement is provided.Less than full engagement is provided at the expansion space 24' betweenblocks in groups 20: and the blocks 22 immediately above them, but aswill be seen from Fig. 2, the blocks 22 which are immediately above theblocks in groups 20: also extend over and asst, fully engage certain ofthe blocks in the adJacent groups 2W of hanger engaging blocks.

From the foregoing it will thus be apparent that the expansion spacebetween adjacent sections is effectively bridged to provide full andpositive interengagement of all of the blocks against lateraldisplacement, without resort to either special block shapes for thispurpose or special metal locking devices. This provides importantpractical advantages since it does not increase the number of differentparts required for the construction of the wall and further does not atany place decrease the edective depth of refractory thickness of thewall.

As will readily be seen from Fig. l, the above described constructionprovides a refractory wall structure of uniform thickness having a planeunobstructed outer surface over the entire area of the supported blocks,which area constitutes substantially the entire wall area. This makesthis wall structure particularly adapted for the application ofinsulation directly to the outer face of the refractory. Thus,-insulating material is readily applied in the most convenient form,namely, in blocks or slabs commonly known to the trade as bats. Suchmaterial is shown at 2t in Fig. 1.

Bats of insulating material are available commercially in differentstandard thicknesses and it will be appreciated that depending upondifferent circumstances in diflerent cases it may be desirable to employdifierent thicknesses of insulation on different walls.

In accordance with another feature of the present invention, means isprovided whereby I bats of insulating material of diflerent thicknessesmay readily be held in position in contact with the refractories withoutrequiring any change in the wall structure. To this end, the hangercastings are provided with lugs on their upper and lower flange portionsshaped to act as retainers for rods or the like which act to hold theinsulation in place, a series of such lugs being provided on each facespaced at different distances from the plane of the web portion of thehanger, so as to be located at different distances from the outer faceof the refractory wall after the wall is erected.

In Fig. 3 two such lugs 28 are shown on the upper flange I8b of hangeri, these being of U-shaped form opening inwardly of the wall and adaptedto hold a retaining rod such as that shown at W. The lower flanges ofthe hangers are provided with L-shaped lugs 32 correspondingly spaced.After the refractory wall has been erected, the bats of insulation areplaced against the outer face of the wall. Rods are then set into thesockets formed by the U-shaped lugs 28 and the outer face of the hat ofinsulation and are then moved into their final retaining position bymoving the upper ends of the rods laterally into position between theouter face of the insulation and the appropriate one of the L-shapedlugs 32.

The form of construction embodying the present invention is also readilyadapted for the construction of a wall of greater refractory thicknessthan that Just described and such a wall is illustrated in Figs. 8 to11, to which reference will now be had.

The construction of the outer supporting frame work and hanger castingsis essentially the same as that previously described and need not againbe described in detail.

In the present construction the hanger engaging blocks 2% are of thedescribed but in the present instance this same shape of block is usedfor making up the courses of supported block 22, both supporting and supported blocks being placed with their longest dinlqlension at rightangles to the plane of the we As will be seen from Fig. 8, the supportedblocks 22' are laid so as to overhang the supporting blocks 23 and aswill also be observed from this figure and Fig. 10, certain of thesupporting blocks ft do not engage the hanger castings but are supporteddirectly on blocks 22' of the top course of the subjacent section. Theoverhanging relation of the supported blocks to the supporting blocksleaves horizontally extending recesses in the wall in front of the innerends of the blocks lit and these recesses are filled by means of fillerblocks 3t having projections Mo on two sides and corresponding groovesMb on the remaining two sides. These filler blocks are supportedentirely by the top course of supported blocks 22' of the subjacentsection.

In Fig. '12 a slightly difierent form of hanger casting is illustrated.In this form, instead of the provision of lugs of the kind shown at Wand 32 in the previously described embodiment, the casting is providedwith vertically extending top and bottom webs 36, each having a seriesof holes til formed therein at diiferent distances from the plane ofthweb of the casting. These holes 38 provide means for attachment ofretaining wires til which may be located at appropriate differentdistances from the outer face of the refractory wall toaccommodatedifferent thicknesses of insulating bats.

In some instances, particularly in the case of high temperaturefurnaces, it is desirable to provide for horizontal as well as verticalexpansion, particularly with respect to the portions of the refractorieson the furnace side of the wall, which are subjected to the highesttemperatures and which consequently have the greatest range of expansionand contraction. This may readily be provided for and insured with wallstructures embodying the present invention, by the use of refractoryshapes of the form shown in Figs. 13 and 14.

Referring more particularly to Fig. 13, which illustrates a supportedblock shape, to be used in the manner similar to the shape shown in Fig.7, it will be seen that the block He is provided with a. projection 22fat one corner and a corresponding recess 289 at the opposite end of theblock. It will further be noted. however, that the projection 22! issomewhat longer than the depth of the recess 22g so that when the blocksare laid end to end in the manner shown in the figure, a clearance space22h is provided between horizontally adjacent blocks except for a verysmall portion at the outer face of the wall. The difference between thelength of the projection and the depth of the recess is advantageouslyof the order of a sixteenth of an inch, to give approximately thisamount of clearance space between individual bricks. This clearance can,of course, can be varied as desired. By making the blocks of this form,allowance for desired clearance is insured regardless of how the blocksmay be laid up by the erector of the wall.

It will further be observed that this construction provides a broken orship-lap joint between adjacent blocks in the same course and since thisship-lap Joint is present, the projections and grooves on the ends ofthe blocks may, if desired,

e shape as previously be omitted as in the blocks illustrated in thefigure. Obviously, the grooves and projections on the block ends, asshown in Fig. 7, may be retained in addition to the ship-lap feature. Itfurther will be evident that in the form of blocks shown in Fig. 7, inwhich the ship-lap feature is omitted, the grooves and projections onthe ends of the block provide a joint between adjacent blocks which isbroken and which operates as a deterent to leakage in the manner of theshipiap joint.

From the preceding description of the supported block shape shown inFig. 13, the similar construction of the ship-lap form of supportingblock 206, shown in Fig. 14, will be apparent and need not be describedin detail.

The interengaging construction which provides a positive interlockagainst inward displacement of the tile toward the furnace isparticularly useful in connection with insulated walls because of thefact that in erecting the insulation there is ordinarily a tendency toproduce pressure tending to force the refractories inwardly of thefurnace and because of variations in thickness of insulation and othervariations or irregularities in erection there may be'a substantialinitial and remaining pressure tending to force the walls inwardly oftheir normal position. Consequently, in this form of wall it is highlydesirable to have a firm and positive lock resisting inward displacementunder the influence of such forces.

It will be apparent that many specific variations in the constructionand arrangement of the wall structure may be made without departing fromthe principles of the invention. Thus, the specific construction of theouter supporting wall structure or framework may be varied as desired asmay also the specific shape and arrangement of the hanger means. Whileseparate hanger castings are to be preferred, it will be apparent that ahorizontally continuous casting may be employed with the bottom flangerecessed or cut away at intervals to permit desired ones of thesupporting blocks 20 to be supported by the refractories of thesubjacent section of the wall. Also, the grouping of the supportingblocks which engage the hangers and which are supported by the subjacentsection may be varied as circumstances require, it being suflicient insome instances to have only single ones of the blocks 20, at spacedintervals, supported by refractories of the subjacent section. It willfurther be apparent that blocks which are to be supported byrefractories of a subjacent section do not necessarily have to be of thesame shape as the hanger engaging blocks. For example, it will beevident that the desired interengaging action will be secured if blocksof the shape of block 34 are substituted for the blocks having the shapeof block 20 in the groups 202 or in the groups corresponding thereto inthe form of the wall shown in Fig. 8. Practically, however, the use ofsuch special shapes is not ordinarily desirable because of the greaterpractical importance of being able to erect the wall from a minimumnumber of block shapes.

It is accordingly to be understood that the invention is limited in itsscope only by the scope of the appended claims when they are construedas broadly as is consistent with the state of the prior art.

What is claimed is:

1. A sectional refractory wall structure for furnaces and the likecomprising horizontally extending vertically spaced hanger structureproviding horizontally extending spaced recesses for the reception ofhanger engaging supporting blocks, courses of supportingblocks insertedin said recesses and projecting therefrom, a plurality of courses ofsupported blocks supported by each of said courses of supporting blocksto provide a plurality of horizontally extending belts or sections, saidsupporting and supported blocks having interengaging projections andrecesses for preventing lateral displacement of the blocks relative toeach other and certain of the blocks in each supporting course beinglocated between said spaced recesses of the hanger structure andderiving their sole vertical support from and inblocks of the subjacentsection, whereby to prevent lateral displacement of said top course ofsupported blocks relative to the bottom course 0 blocks of thesuperjacent section.

2. A refractory wall structure for furnaces and the like comprisingouter supporting structure, a plurality of horizontally extendingvertically spaced rows of hangqcastings carried by said outer supportingstructure, the hanger castings of each row being spaced from each otherand providing horizontally extending spaced recesses, a plurality ofspaced groups of supporting blocks engaging the recesses in the hangersof each row, a plurality of continuous courses of supported blockssupported by the groups of hanger engaging blocks of each row to formhorizontally extending belts or sections, and refractory blocks locatedbetween each two adjacent groups of hanger engagin supporting blocks,said refractory blocks being located between said spaced hanger castingsand being vertically supported by the top course of supported blocks ofthe subjacent section and the refractory blocks having projections andrecesses interengaging with complementary recesses and projections ofthe hanger engaging blocks of the same course and of the course ofsupported blocks providing the vertical support, whereby the refractoryblocks operate to prevent lateral displacement of the top course ofblocks of the subjacent section relative to the bottom course of blocksof the superjacent section.

3. In a refractory sectionally supported wall structure, a bottom courseof supporting blocks 50 for each section of the structure, an outersupporting structure having spaced horizontally extending recesses,certain of said supporting blocks engaging the recesses in said outersupporting structure and deriving both vertical and lateral 55 supporttherefrom, certain other blocks of said course deriving vertical supportfrom the top course of a subjacent section, all of said blocks havinginterengaging projections and recesses for preventing lateraldisplacement of any one of the blocks relative to the blocks adjacent toit, whereby to prevent lateral displacement of the top course of blocksof the subjacent section relative to the bottom course of blocks of thesuperjacent section.

4. A sectionally supported refractory wall structure comprising aplurality of horizontally extending vertically spaced hangers providingrecesses for the reception of refractory blocks, a plurality of oblongsupporting blocks inserted in said recesses and projecting therefrom,said supporting blocks being arranged with their longest dimension atright angles to the plane of the wall and the projecting portionsthereof having projections and recesses thereon extending trans- 75versely of the blocks in the plane of the wall. a

terengaging with the top course of supported plurality of courses ofsupported blocks carried by said projecting portions, and said supportedblocks having projections and grooves extending parallel to the lengthsof the blocks, said supported blocks being laid lengthwise in the planeof the wall and said grooves and projections of the supporting andsupported blocks interengaging to prevent lateral displacement of theblocks relative to each other, and means comprising refractory blockssupported by the top course of supported blocks and interengaging thesame and the blocks of the bottom course of a superjacent section forpreventing displacement of said top course of supported blocks relativeto said bottom course of said superjacent section.

5. A refractory sectionally supported wall structure comprising aplurality of horizontally extending vertically spaced hanger meansproviding horizontally extending recesses for the reception ofrefractory blocks, a plurality of oblong refractory supporting blocksinsertedin said recesses and projecting therefrom, each of saidsupporting blocks having two spaced sets of transversely extendingprojections and recesses, the projections of one set engaging with saidhanger means and the projections and grooves of the second set beinglocated on the projecting portion of the blocks, a plurality of coursesof supported blocks of similar configuration as that of the supportingblocks, said supported blocks being overhung with respect to thesupporting blocks and projections and grooves thereon interengaging withthe projections and grooves on the projecting portions of the supportingblocks, and a course of filler blocks between the inner ends of saidsupporting blocks and the inner face of the wall, said filler blocksbeing supported by the overhung portions of the top course of supportedblocks of a subjacent section.

6. A refractory sectionally supported wall comprising a plurality ofindependently supported horizontally extending belts or sections ofrefractory blocks, each comprising a plurality of courses of supportedblocks and a bottom course i of supporting blocks, said supportingblocks extending outwardly beyond said upported blocks and engaginghanger members to independently support each section, said supportedblocks providing plane outer wall surfaces between said courses ofsupporting blocks, bats of insulating material in contact with saidouter surfaces, retaining rods for holding said bats in position andmeans formed on said hanger members for holding said retaining rods inposition.

7. For use in refractory wall structures, a

hanger casting of generally channel section providing a web portionadapted to be secured to an outer supporting structure and upper andlower flange portions adapted to engage a refractory block to besupported thereby, said flange portions each being provided with a.series of retaining lugs and the lugs of each series being spaced atdifierent distances from the plane of said web portion.

8. For use in refractory wall structures, a hanger casting of generallychannel section providinga web portion adapted to be secured to an outerSupporting structure and upper and lower flange portions adapted toengage a refractory block to be supported thereby. said flange portionseach being provided with an ex temal web extending substantially atright angles to the plane of the web portion of the member and each ofsaid webs having a plurality of holes therethrough located at diiferentdistances from the plane of said web portion.

9. A refractory block for furnace walls and the like, said block beingof generally rectangular oblong shape and having a projection at one endand a recess at the opposite end providing shouldered end faces, saidprojection having greater length than the depth of said recess, wherebyto provide shoulders of different depth on the opposed ends of the blockand to thereby provide a clearance space between portions of the endfaces of adjacent blocks when the blocks are laid end to end with theprojection of one block seated in the recess of the adjacent block.

10. A refractory block as set forth in claim 9 having a projectionextending longitudinally of the block on one side face thereof and acorresponding groove extending longitudinally of the side face of theblock opposed to the face having said projection.

11. A refractory block for furnace walls and the like, said block beingof generally rectangular shape, a projection extending from one sideface at the corner of the block, a recess correspondingly located in theopposite side face of the block, said projection and recess providingshouldered opposed side faces and the height of said projection beinggreater than the depth of said recess whereby to provide clearance spacebetween adjacent side faces of adjacent blocks when the blocks are laidup with the projection of one block in the corresponding recess of anadjacent block.

12. A block as set forth in claim 11 in which the non-shouldered sidefaces of the block are provided with at least two sets of transverselyextending grooves and projections.

13. A sectional refractory wall structure for furnaces and the likecomprising horizontally extending vertically spaced hanger structureproviding horizontally extending recesses for the reception of hangerengaging supporting blocks. courses of supporting blocks inserted insaid recesses and projecting therefrom, certain of said blocks in eachcourse being spaced horizontally from adjacent supporting blocks, aplurality of courses of supported blocks supported by each of saidcourses of supporting blocks to provide a plurality of horizontallyextending belts or sections, said supporting and supported blocks havinginterengaging projections and recesses for preventing lateraldisplacement of the blocks of each course relative to each other, andlocking blocks in each supporting course located in the space betweencertain of said supporting blocks and deriving their sole verticalsupport from the top course of supported blocks of the subjacentsection, the sides of said locking blocks interengaging with adjacentsupporting blocks and the bottoms of said locking blocks interengagingwith the top course of supported blocks of said subjacent section,whereby to prevent lateral dis-.- placement of said top course ofsupported blocks relative to the superjacent course of supportingblocks.

PHILIP WASHINGTON ANTIIL.

